Wireless Innovations Improving Productivity - … Innovations Improving Productivity 1 2 ... WWi....

Wireless Innovations Improving Productivity

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Improved ProductivityAdditional Production Output

CORRECT ISSUESImmediate Communications

DISPLAY ISSUESVisual Display Software

ANALYZE ISSUESGraphs and Reports

PREVENT ISSUESCorrective Action

VT3000Innovative

Wireless System

For the Production Floor

WWi

Immediate Communications

Visual Management

Automatic Data Collection

Visual & Audio Andons

Real Time Performance Visibility

Factory Floor Communication • Andons • Real Time Performance Screens • Visual Factory • Automated Data Capture • OEE

Eliminate Production Looses

Recover Lost Production Time • Minimizing Production Disruptions – Reduce Downtime • Identifying & Immediately Correcting Production Abnormalities • Immediate Communications of Production Issues

Visual Management • Performance Feedback to Line Operators • View Equipment or Production Station Status • View Line Status & Plant Status • Enterprise Status

Easily Identify Process Bottlenecks/ Areas for Improvement / Track Week to Week Improvements

Automatically Capture Performance Data

Significantly Improving the Accuracy /Timeliness/Consistency/Completeness of the Data


VersaCall’s Customer’s include …


Supports All Manufacturing Environments

Machine Centers

Moving Assembly Lines & Stationary Assembly Operations

Packaging Line

Cell Manufacturing

Process Flow Lines

Production Lines


VersaCall Success Stories

Turning Lost Downtime Into Productive Time

Qualifying Root Cause of Issues for Process Improvement

Visual Management - One Screen Complete Line Visibility

Efficient and Timely OEE Reports Improves Output


8 Hours of Downtime Turned Into Productive Time – 1st Month

250 Calls 1st Week - 70% Related to Material Issues

Individual Assembly Line Status

• Line Output

• Takt Time Performance Actual vs. Target

• Lost Production Time

• Individual Work Zone Status

Eliminated All Manual Data Collection – Immediate OEE Reports

Financial Return – Payback 2 to 6 Months

Financial Paybacks Are Realized From: Reducing Downtime – Immediate Communications of Issues

Reducing Set-Up Time

Automated Data Collection

Real Time Monitoring of Production Status – Identifying Abnormalities

Complete System Start at $7,500

Customer Example –System & Payback VT3000 System - $10,100 • Control Unit [Server] with Receiver

• 10 Input Modules – Call Stations

• 1 Repeater

• Large Screen Display Software

• 2 Way Radio Transceiver

Financial Payback – 3.2 Months (Annual Return $37,500)• 30 Incidents [10 Per Shift] – Total Plant – All Shifts - 4 Minute Savings Per Incident

• 3 Employees Affected Per Incident

Templates at Available For Calculating ROI


New Andon Technology Un- Paralleled Performance Visibility LED Light is completely Programmable

Innovations in Visual Management

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System Overview

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System

Repeater Wireless

Powered

System

Receiver

Input

Modules VT 3000 Std Control Unit / Server

REAL-TIME SCREENS

SMART PHONES, TABLETS

& REPORTS

TOUCH INPUT MODULE

Call Station Input Module

Call Station - Battery or Powered

Captures Response Time to Issues

Introduces a Whole New Concept of Support Accountability

Also Escalates and Routes Messages Until Acknowledgement

Every Request for Support is Logged in Database [Time and Date Stamped ]

Provides Visibility of Support Personnel Response Performance to the Production Floor

Innovative Zigbee Wireless “Mesh” Technology

NEMA 4-sealed housing / Membrane Switch Buttons

Contains 4 Switch Contacts

Up to 1,500 Units per System – 6000 Monitoring Points in Control Unit [Server]

Communication Path for Each Individual Button is Programmable


DigiMesh Technology Forms

It's Own Network

BSC Input Module - Flexible and Simple

BSC Module – Programmable Buttons


Touch Screen

I/O Module

• Choose Button Type, Color, Size & Quantity • Flexible Layouts • Programmable • Link Multiple Screens • Immediate Communications • Simple & Flexible

Touch Input Module - Visual Status Indicators

Programmable & Configurable Touch Screen Displays

Number of Individuals to Call – Programmable 20+

Immediate Communications -Response Time & Escalations

Captures Counts & Downtime With Reasons

Full Touch Screen Keyboard & Key Pad


Touch Input Module – 7” Screens

Production Status Module – Touch Screen [10” Screen] & I/O Module

Module Features

• Configurable Touch Screen Display

• Captures the Responding Individual w/ NFC Technology

• Module Retrieves Data for Look Up List

• Wireless Configuration Set-Up & Changes

• Supports Wireless Bar Code Scanners

• Clear Alarms/Actions from Different Modules

• Full Communication Capabilities

• Full Touch Screen Keyboard & Key Pad


Completely Configurable Screens

VESA Mounting Patterns Supports

Multiple Stand Options

Bench Stands Floor Stands

EquipmentMounts

Articulating Arms

Touch Input Modules

Touch Screen ApplicationsVerification of Certified Operator or Trained Operator

Verifies that the operator has been trained on the equipment . Can Set-Up so Operator Must Perform Function Before Starting Equipment. Can have immediate communications to floor supervisor when there is an issue.

Check List

Can Set-Up so Operator Must Perform Function Before Starting Equipment.

Can be a Dynamic List –Change by Location or Station or Part Number

Request Material Including Quantities

Operator Pushes “Material Button” – List appears & operator select the material required. Material List is can be a

“Dynamic List” - it can be different by locations or Part Number being produced. Options to request the quantities required.

Run Jobs or Production Runs In Sequence

Production runs or job numbers that are to be run are loaded into the system by line management. Job sequence is shown on the touch screen.

Touch Screen Programmable Indicator Status

8 Programmable Indicator Status On the Screen - Each Screen Can Have It’s Own Indicators – Colors Change to Reflect Status


Additional Modules

• Unit


Wireless Switch Contact Module – Input Module

Moving Assembly Module

1Wireless

• Simple Inputs

• Normally

Open/Closed

• Fully Programmable

Repeater

Wireless Controls Module

I / O Module 1Wireless

• Full Communications

• Simple to Use – One Button to

Signify Work Complete

• Captures Assembly Performance

within Assembly Line

• Automatically Resets

1Wireless

• Machine Interface

• 4 Inputs

• 7 Outputs

• Inputs Can Control Outputs

1Wireless Activation

• Lights

• Horns

• Speakers

Inputs Can Control Outputs

Program remotely

1Computer Screen ModulesPC Modules

For LAN Connected PC’s

Touch Screen or Mouse

PC Call Station Add’l Buttons Can Be Added

PC Input Module Flexible –Layout Completely Configurable

Primary Applications

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Machine Monitoring Applications • Captures Lot Number or Production Run Performance Information

• Captures Scrap by Reason Code / Downtime by Reason Code

Andons & Communications • Audio & Visual Andons

• Immediate Communications of Issues

• Wired & Wirelessly Activated Modules

Moving Assembly Line• Simple – Operator Input

• Measures Each Segments Performance

• Identifies Pacing Segment

Stationary Assembly Operations • Measures Assembly Activity Against Standards

• Visibility Status of Assembly Activity

• Immediate Communications of Issues

OEE • Complete System – Data Capture to Reporting

• Eliminates Manual Data Collection

• Critical Visibility for Addressing Issues

Innovative Software that Expands The System Capabilities

Software Tools That Allows Customers to Easily Modify & Reconfigure Their System’s Operation

VT3000 Advanced Monitoring Software – AMS

What It Provides

The AM Software provides the capability to monitor for a status or a condition. When this status or condition occurs specific pre-defined actions are initiated.

AMS - Powerful Tool for Easily Developing Custom System Solution

VT3000 Advanced Scheduling Software

What It Provides

The AS Software provide the capability to schedule predefined specific actions. These actions can be for set times or linked to shifts.


Innovative Approach for Capturing Operational Performance – Accomplishment

Measure Performance Status by Measuring Accomplishment

Applies to Manufacturing That Does Not Have Standard Performance Measurement

One of a Kind Production – Custom – Large Unit Assembly

Allows You to Measure What You Have Not Been Able to Measure in the Past

• Immediate Visibility of Unit Completion Status

• Customizable & Adaptable to Any Type of Unit or Version of the Unit

• Simple – Measure Accomplishment or Task Completion

• Line Personnel Simply Checks a Box When Individual Task

is Completed or Accomplished

• Flexible – Can Be Utilized for End Units or Sub-Assemblies Units

• Instant Communication of Issues


Multiple Outputs Options

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Audio Andons - Wireless Horns

MP3 Player - Up to 105 dB

Any Sound / Tune / Music

Andon Lights

Sizes Up to 100MM

Poles up to 10’ +

Vehicle Mounted Display

Forklifts, Tuggers, Lift Trucks

Wireless

2 Way Radios & Transceiver

Supports Up to 8 Channels

On- Site Paging Transmitter

On-Site Pagers

2 Lines - Easy to Read

E-Mail

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Desktop & Cell Phones

Completely Integrated Visual Andon Systems A New Dimension in Visual Communications for the Production Floor - Virtual Panel IV Display Software

Fully Integrated Andon Systems

From Input Modules to Displays


Input Modules

Production Schedule

Production Activity Status

Communications Support Request

Virtual Panel IV Software New Panel Software

• Systematic Panel Generation Process• Wizard Guides Panel Development • Significant Reduction in Panel Creation Time • Improved Options in Panel Development Choices • Easy Correction Feature

VP IV Software Right Sizes to Device – Same Screen on a Smart Phone as Large Screen Display

Visual Management – Real Time Production Status Visibility

Linking Communications With Visual & Audio Andon Notification

Un-Paralleled Performance Visibility


Operator / Cell / Equipment Performance

Material Support

Line Performance – Stack Lights

Production Floor - White Boards

Android & iPad Tablets

Smart Phone KPI’s

Visual Management

Unique Visual Management Solutions Updating Graphs & Real Time Performance Information


Virtual Panel IV Software Andon – Messaging- Performance – Plant Layout – Informational

VP IV Software

Multiple Layout Options / Flexibility

• Type of Information Displayed

Plant Wide Information Messages

Factory Floor/ Line Performance Status

Real Time Performance Status

• What is Displayed

Text, Images, Scrolling Messages, Counts, Duration

Calculations, Conditional Messages, States, Formulas

• How Information is Displayed

Choose Font Size, Font Types, Font Color, Flashing

Panel or Flashing Letters, Real Time Update Rates

• Where / Sequence of Information

Target Specific Areas

Entire Plant

• User Friendly Tools –On Line


Interactive On-Line Session

Design Your Own Screen Layouts

• Start With Example Templates

Andons / Messaging / Informational / Performance / Combo

• Using Step by Step Wizards

Develop Screen Layouts

Process Takes 20 Minutes

Final Layout that Fits Your Needs

• Alternative - Developing Custom Screens Layout Solutions

Andons

Messaging

Informational

Combo

Performance

Plant Layouts

VersaCall Reporting Software II Software That Produces Trend and Comparison Graphs & Reports That Are Easy to Create and Change

Template Approach Provides Rapid Report GenerationOther Features

• Automatic Report Generation Feature Reports Automatically Created for Shift , Day , Week - Sent Directly to Your E-mail

• Clear /Concise Graphs & Report Formats

Immediately Spot Issues & Root Causes – Simple Red/ Yellow / Green Designations

• Financial Performance Impacts Feature

Reports that Profile the Cost of Downtime & the Cost of Scrap

• Configure Custom Reports & Graphs Adding In Your Own Title & Logo

• Apply Standards & Target References

Pull Reference Standards for Existing Databases or Look Up Tables Using Data Look Up Manager

• Step by Report Generation Using Wizards & Choosing Templates


Summary of Additional System Features and Capabilities

Verification of Certified or Trained Operators On Machines – immediate communication

to floor supervision when there is a issue.

Lock Out – Reason Code must be selected before the equipment can be re-started

Secondary Communications – After a defined period has lapsed, then a secondary communication path is initiated for an incident

Integration with Existing Software System – Non Invasive – Site is in complete control

Look Up Tables – Flexibility to set up varying shifts , Breaks , Lunch Period

Advance Monitoring Software – Predefine a set of parameter triggers & actions – system monitors for the parameters

Advanced Scheduling Software – Predefined trigger based upon a date, time or a count,

System monitors for the date, time or count

Preventative Maintenance Packaging is in Development

System Monitoring Software - Software That Insures Your VT3000 System is OperationalFactory Floor Communication • Andons • Real Time Performance Screens • Visual Factory • Automated Data Capture • OEE

Moving Forward - Identifying Your Application

Step 1 - Start Small - Identify One or Two Critical Problem Areas

Step 2 - Clearly Identify the Results You Want To Achieve - Define Your System Solution – Metric Visibility

Visual Performance Visibility

Trend & Analysis Reports and Graphs - Performance Information That Makes a Difference

Step 3 - Work with VersaCall to Develop an Application Profile

Lay Out a Solution for Addressing the Problem Areas - Including the Modules & Financial Justification

Also Installation & Configuration Packages Available


For Developing a System Solution – We want to start where you want to end.

PerformanceMessaging

Communications

Information Andons Design You Own Layout

Downtime TrendsPerformance Download to Excel

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